Apparatus for applying coating to products and methods of use thereof

ABSTRACT

An apparatus and method for coating products is disclosed herein. An exemplary method includes receiving coating at an inlet end of a pan assembly for application to a product, vibrating the pan assembly using a vibratory frame assembly connected thereto, positioning the product at the inlet end of the pan assembly, removing excess coating from at least a portion of the pan assembly, receiving the product at the discharge end of the pan assembly, and receiving the excess coating at the discharge end of the pan assembly and transporting it to the inlet end of the pan assembly.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation application of U.S. application Ser.No. 12/271,632 filed on Nov. 14, 2008. The 12/271,632 application is acontinuation-in-part application of U.S. application Ser. No. 12/126,610filed on May 23, 2008, issued as U.S. Pat. No. 7,757,836, and claimingpriority to U.S. Provisional Application Ser. No. 60/940,247 filed onMay, 25, 2007. The 12/126,610 application is further acontinuation-in-part application of U.S. application Ser. No. 11/396,202filed on Mar. 30, 2006, issued as U.S. Pat. No. 7,703,411, and claimingpriority to U.S. Provisional Application Ser. No. 60/667,405 filed onApr. 1, 2005. The 12/271,632 application also claims priority to U.S.Provisional Application No. 61/083,777 filed on Jul. 25, 2008 and U.S.Provisional Application Ser. No. 60/990,566 filed on Nov. 27, 2007. Allpatent applications listed above are incorporated herein by reference.

FIELD OF THE INVENTION

The field of invention includes coating and conveying equipment.

BACKGROUND OF THE INVENTION

Prepared food products come in a wide variety of styles. Many preparedfood products, whether ready-to-eat or those needing further cooking,are prepared with a coating that makes the food product more appealing.Such prepared food products include entrees, appetizers, desserts (suchas pastries, donuts), etc., and includes meats, cheese, fruit andvegetables, etc. The types of coatings used on these food productsinclude dry coatings such as flour, bread crumbs, corn meal, sugar andspice and the like.

In the food preparation industry, food coatings are generally classifiedby appearance as flour breading, free flowing (such as cracker meal orbread crumbs), and Japanese-style crumbs which tend to be elongate andcrispy. Food coatings may also include seasonings, spices, shortening,etc., as needed to add flavor and texture to the food product. Othercoatings such as ground cereal, dried vegetables or the like, may alsobe employed.

Each coating mixture has inherent characteristics that presentchallenges to machinery used to automatically and mechanically coat foodproducts. For example, flour mixtures, which consist of finely grounddust-like particles, have a tendency to pack under pressure, therebydecreasing the free-flow properties of the coating mixture around thefood product, which can decrease coating uniformity. Similarly, coatingmixtures recognized as free-flowing include reasonably hard and roughlyspherical particles ranging in size from dust to larger particles, suchas cornmeal, cracker meal or the like. Free-flowing mixtures inautomated coating processes can often flow or leak out of the machinery.

Japanese-style crumbs have no uniform shape, are very delicate, and arecrystalline-like in nature and appearance. So, the coating machineshould be able to properly handle this type of breading material toavoid degradation of the quality and particle sizes thereof.Japanese-style crumbs consist of modified wheat flour with smallpercentages of yeast, salt, sugar, vegetable oil and other additives.The Japanese-style crumbs appear to be dried shredded white bread havingparticles ranging in size from as large as ½ inch to as small as floursize particles.

Some food products have a batter applied to them before the coating ortopping is applied. When a batter applicator is used before the coatingor topping is applied, time is saved when both the batter applicator andthe coating or topping run at the same or similar speed and when bothhave the same or substantially similar product output width. Thisprovides a continuous flow of food product during both processes. Theseattributes are also helpful in non-batter applications, such as goingfrom a breading application to a frying application.

While the automation of the food coating process is economicallydesirable, another goal of the food coating process is to make thecoating appear to be “home-made.” However, most automatic food coatingprocesses fail to make “home-style” appearing foods. In the commercialproduction of prepared foods, a large variety of food products aremachine-coated with breading, flour or the like before being fried, (orotherwise cooked) or simply frozen and packaged.

Some food products have what is called a “home-style breading,” whichsimulates a breaded food product prepared in the home. This can be done,for example, by dipping food, such as pieces of raw chicken, in a bowlwith beaten egg and then placing the egg coated food into a bagcontaining flour and optionally spices, herbs, seasonings, shortening,etc., to form a coating which adds flavor and texture to the product.Other coating material such as ground cereal, dried vegetables or thelike may be used as desired. The bag is moved back and forth to coat themany surfaces of the food product. This technique can be useful forcoating food products having many, oftentimes hidden surfaces, such aschicken, because in moving the bag, the surfaces of the food productsare exposed to the coating. The technique is also useful for coatingvarious other food products. The flour coated food is then fried in afrying pan or deep fryer in the home.

Generally, the food industry prefers to use an automated and continuousfood coating process wherever possible while still achieving a“home-style” look. In the food processing industry, home-style breadingfood products have been prepared using a drum type breading apparatus,wherein a food coating, such as flour, is added to a hollow drum withaxial ribs along inner surfaces of the drum. The food products to becoated are added to the drum via a first conveyor that drops foodproducts into the drum. The drum rotates so that the food products aretumbled along with the coating. The tumbling process unfolds foodproducts that are folded and exposes surfaces of the food products tothe coating. Although producing a desired coating appearance andtexture, particular problems encountered in a drum breader include thefood products being collected in a pile at the bottom of the drum. Thepile of coated food products is deposited on the center of a secondconveyor belt that takes food products away from the drum. Therefore,food exiting on the second conveyor belt must be spread and alignedalong the width of the conveyor belt before it goes to anotheroperation, such as freezing. This adds another step to the processing offood products. It also can result in low quality food products if foodis not properly redistributed along the conveyor width. For example,food can be clumped together and then the next step in the foodprocessing is not carried out in an optimal way. Where food is frozenafter being on the second conveyor, clumps of food can be frozentogether, making weighing, cooking, and packaging of it very difficultand oftentimes resulting in costly waste. In addition, drum stylebreaders are often difficult to clean and require intensive maintenance.

The use of a drum breader has many disadvantages, particularly when usedon a high capacity manufacturing line. The first disadvantage is thatthe product is discharged from a drum breader in a narrow pile and mustbe then spread back out to the typical line width which can be 3-4 timesthe pile width. This process is often done with an additional piece ofequipment placed after the drum breader. Additionally, many processorsalso like to align and lengthen food products such as a chicken stripbefore they go into a fryer or freezer to maximize the line capacity andalso provide a more visually appealing product. This task is alsoaccomplished using an additional piece of equipment placed after thedrum breader.

Further, the drum breader is not very effective at sifting flour thathas not adhered to the food product. Because of this, excess coating isoften discharged from the drum breader along with the food product whereit either falls to the floor causing waste or is carried down streamcausing problems with further processes such as ruining the oil in afryer. Additionally, due to the size of the drum breader and because ofthe ancillary equipment that is often needed to spread and align theproduct after it, home style lines can get very long and therefore canbe difficult to accommodate.

Other types of food coating devices employ endless mesh belts. Forexample, U.S. Pat. No. 6,117,235 discloses a continuous coating andbreading apparatus which includes a conveyor belt made of stainlesssteel mesh. The conveyor has various stations along its length. Fooditems are deposited on the belt at an infeed area and are coated withthe coating mixture on the bottom surface. The conveyor belt carries thefood items under a “waterfall” of food coating that covers the topsurface of the food items. The conveyor passes under one or morepressure rolls that pat the coating mixture onto the food pieces, and/ora blow off device, removing excess coating. The coated food product isdeposited at a discharge area. In commercial practice, such systems mayemploy as many as six conveyors to spread the coating mixture andachieve acceptable consistent operation and performance. Further, as itis customary to use a drum breader for applying a coating to durablefood products that require agitation to fully coat, such as chicken, anda mesh conveyor belt to apply coating to fragile food products, at leasttwo machines are required. The use of two machines requires extra spaceand extra maintenance.

BRIEF DESCRIPTION OF DRAWINGS

Embodiments of the invention are disclosed with reference to theaccompanying drawings and are for illustrative purposes only. Theinvention is not limited in its application to the details ofconstruction or the arrangement of the components illustrated in thedrawings. The invention is capable of other embodiments or of beingpracticed or carried out in other various ways. The drawings illustratea best mode presently contemplated for carrying out the invention. Inaddition, although not used exclusively, when used, like numerals havebeen used to identify like components throughout. In the drawings:

FIG. 1 is a right side view of an exemplary embodiment of an apparatusfor applying coating to food products including, a vibratory frameassembly, a pan assembly, and a coating recycle assembly.

FIG. 2 is a left side view of the apparatus for applying coating to foodproducts of FIG. 1.

FIG. 3 is a top view of the apparatus for applying coating to foodproducts of FIG. 1.

FIG. 4 is a discharge end view of the apparatus for applying coating tofood products of FIG. 1.

FIG. 5 is a right side view of the vibratory frame assembly of FIG. 1.

FIG. 6 is a right side view of the pan assembly of FIG. 1.

FIG. 7 is a right side view of the recycle assembly of FIG. 1.

FIG. 8 depicts a system including a metering conveyor along with anexemplary embodiment of an apparatus for applying coating to foodproducts.

FIG. 9 depicts another exemplary coating recycle assembly.

FIG. 10 depicts a portion of an exemplary pan assembly.

FIG. 11 depicts an exemplary coating recycle assembly.

FIG. 12 depicts another exemplary coating recycle assembly.

FIG. 13 depicts an exemplary embodiment of the apparatus for applyingcoating to food products including, a vibratory frame assembly, a panassembly, a coating recycle assembly, a wire conveyor belt assembly in aproduction position, a frame and a swing frame portion.

FIG. 14 depicts the exemplary, vibratory frame assembly, pan assembly,coating recycle assembly and auxiliary hopper.

FIGS. 15A and 15B depict exemplary embodiments of a wire conveyor beltassembly.

FIG. 16 depicts an exemplary embodiment of the wire conveyor beltassembly, the frame and the swing frame portion.

FIG. 17 depicts an exemplary embodiment of the apparatus in FIG. 13,wherein the wire conveyor belt assembly is in a non-production position.

FIG. 18 depicts an exemplary embodiment of the wire conveyor beltassembly, the recycle conveyor, the frame and the swing frame portion.

FIG. 19 is a side view of an exemplary embodiment of the apparatus forapplying coating to food products including, the vibratory frameassembly, the pan assembly, and the coating recycle assembly.

DETAILED DESCRIPTION

In summary, an apparatus and method for coating products is disclosedherein. An exemplary apparatus comprises a vibration generating portionand a food product coating portion. The food product coating portion caninclude a coating application portion, a sifting portion, and analigning portion. The exemplary apparatus can include a coating recycleportion as well. The vibration generation portion further comprises amotor vibration assembly secured to a frame wherein the frame is incommunication with the food product coating portion, such as a panassembly, by springs that move the pan assembly with a vibratory motion.The pan assembly includes at least one of the coating applicationportion, the sifting portion, and the aligning portion. The coatingapplication portion is comprised of a series of inclinations, such asangled steps that guide the coating and vibrating food product upwardsand forwardly while simultaneously allowing the food product to bebounced against the coating resting on the step surface. As the foodproduct is vibrated over the edge of one or more steps, it tumbles andunfolds, thereby exposing non-coated portions to the coating.

The sifting portion succeeds the coating portion wherein the foodproduct continues to vibrate across another series of angled steps ofwhich perforations are formed therein. Unused or otherwise excessivecoating on the food product passes through the perforations as the foodproduct vibrates forward across the steps. The coating that passesthrough the perforations can be collected and guided into a hopperand/or a base recycle conveyor that conveys the coating back to thecoating portion step(s).

The food product continues to the aligning portion that is comprised ofa corrugated surface situated at an incline having channels formed bythe corrugations that are substantially parallel with the length of thepan assembly from an intake end to a discharge end. The channels biasthe food product such that it can be elongated and aligned from thevibration.

An additional sifting portion can be provided that can include anotheraligning portion having holes situated there-through to allowagglomerations of coating or undesirably small food product pieces topass through and thereby be removed from the process. The coated,elongated, and substantially aligned food product can then advance to asubsequent process.

Further, another embodiment of the apparatus and method for coating foodproducts is disclosed herein, wherein the recycle conveyor portionincludes a base recycle conveyor and a waterfall recycle conveyor thatsupplies coating at an intake end of the coating application portion andreceives coating at the discharge end of the pan assembly.

Additionally, another embodiment of the apparatus and method for coatingfood products is disclosed herein, the apparatus comprising a vibrationgenerating portion, a food product coating portion and a recycleconveyor portion. The vibration generating portion includes amotor-induced vibration assembly. The food product coating portion caninclude a pan assembly in communication with the vibration generatingportion, and at least one of a food product path therealong the panassembly, and a food product path along a wire conveyor belt assemblythat is not subject to the vibratory component of the vibrationgenerating portion. The recycle conveyor portion can include one or morerecycle conveyors, such as a base recycle conveyor to provide coating toa loading surface and/or a waterfall recycle conveyor situated toprovide a waterfall of coating to at least one of a bottom and topportion of a food product. The recycle conveyor(s) is configured toreceive coating at a distal end of the food product path and return itto the proximal end of the food path. Further, the apparatus can includea swing frame portion that is secured to the wire conveyor belt assemblysuch that the wire conveyor belt assembly can be moved from anon-production position, wherein the food product path is along the panassembly, and a production position, wherein the food product path isalong the wire conveyor belt assembly. Additionally, the apparatus isnot limited to the application of food based coating and food products,the apparatus can be used to provide a coating of non-food basedmaterial onto a non-food based object.

FIGS. 1 and 2 depict an exemplary embodiment of an apparatus 2 forapplying coating to food products, the apparatus 2 includes a vibrationgenerating portion, such as a vibratory frame assembly 4, a food productcoating portion, such as a pan assembly 6, and a coating recycleportion, such as coating recycle assembly 8. Additionally, FIG. 1depicts a left side of the apparatus 2, and FIG. 2 depicts a right sideof the apparatus 2. Further, FIG. 3 shows a top view of the apparatus 2,more particularly, the pan assembly 6 and the coating recycle assembly8. FIG. 4 shows a discharge end view of the apparatus 2 includingportions of the vibratory frame assembly 4, the pan assembly 6, and thecoating recycle assembly 8.

FIG. 5 shows an exemplary vibratory frame assembly 4 that comprises asupport frame 10, a plurality of isolators 12, at least two vibratoryframe side members 14, at least two vibratory cross-members 15, at leasttwo motorized vibrator assemblies 16, and a plurality of springassemblies 18. The support frame 10 in one embodiment comprises two sidetubular members 20 and each of front and back tubular members 22, 24,respectively. The tubular members 20 can be square in cross-sectionalview and can be secured adjacent their respective ends to form asubstantially rectangular shape. In one embodiment, the length and widthof the support frame 10 can follow the footprint of the vibratory frameside members 14, although it has been contemplated that the supportframe 10 can comprise various shapes, dimensions and configurations toprovide less or more support as necessitated by the operatingconditions.

In one embodiment, the vibratory frame side members 14 (shown in FIGS. 4and 5) are in the shape of an elongated plate having a thickness ofabout ⅝ inches, a height of about 16 inches, and a length of about 96inches. In another embodiment, it has been contemplated that thevibratory frame side members 14 can vary in thickness by about ¼ inch toabout 1½ inches, in height by about 6 inches to about 24 inches, andhave a length that would be substantially similar to the length of thepan assembly 6. Further, because the apparatus 2 can vary in size toaccommodate various types of process configurations of varying scale,the dimensions of the vibratory assembly components can varysubstantially outside of these dimensions. Also, it has beencontemplated that the vibratory frame side members 14 can vary in shapeas well, such as triangular or square. Still further, in one embodiment,two cross-members 15 are secured between, and substantiallyperpendicular to, the vibratory frame side members 14 as shown in FIGS.4 and 5. In another embodiment, fewer or additional cross-members 15 canbe used to provide for various apparatus 2 configurations.

The support frame 10 is secured to the vibratory frame side members 14by the isolators 12. In one embodiment, the support frame 10 and thevibratory frame side members 14 each have mounts such as brackets 17extending therefrom for securing the isolators 12 in a verticalorientation (as shown in FIG. 5), although it has been contemplated thatthe isolators 12 can also be secured in other ways, such as using otherprotrusions 43 or indentations, and at various angles. Further, althoughthe exemplary embodiment depicted has four isolators 12 and eightbrackets 17, it has been contemplated that increasing or decreasing thenumber of these components can provide varying degrees of stability andsupport as required.

The isolators 12 are configured to provide support and isolation andtherefore can vary in size and hardness. In one embodiment, theisolators 12 are constructed using a polyurethane tube that is about 6inches in length and has about a 2½ inch thick wall, and a hardnessrating of 40-60 durometers. Although in other embodiments, thedimensions and hardness can vary depending on the application, forexample from about 2 inches to about 10 inches in length, about 2 inchesin diameter to about 10 inches in diameter, and about 40 to about 70durometers in hardness. The dimensions and weight of the vibratory frameand pan assemblies 4, 6 can at least partially dictate theaforementioned parameters, and therefore the dimensions can varysubstantially.

In one embodiment, the vibratory frame assembly 4 further comprises amotorized vibrator assembly 16 mounted to each of the vibratory frameside members 14. The motorized vibrator assembly 16 is adapted to impartenergy to the vibratory frame side members 14 at an angle β below thehorizontal (as shown in FIG. 5). In an exemplary embodiment, β rangesfrom about 15 degrees to about 60 degrees, for example, about 45degrees, although in other embodiments β can vary more or less. In anexemplary embodiment, the motorized vibrator assembly 16 includes amotor 28 coupled to a pair of eccentric vibrators 30, for example, apair of rotary magnetic vibrators such as the Motomagnetic electricvibrator as manufactured by Martin Engineering Nepoinset, Ill. ModelST12-1440. In one embodiment, the motor 28 is speed-controlled by aninverter (not shown), such as the POWERFLEX 40 as manufactured by AllenBradley, although in another embodiment a hydraulic speed control can beused, for example of the type manufactured by Sun and Bosch. Further,the energy imparted to the vibratory frame side members 14 by themotorized vibrator assembly 16 is at least partially transferred fromthe vibratory frame assembly 4 to the pan assembly 6 by the plurality ofspring assemblies 18.

Referencing FIGS. 6 and 10, an exemplary embodiment of the pan assembly6 is depicted comprising of a pan bottom portion 34, pan side portions37, at least one step 36, of which forms a coating application portion,at least one perforated step assembly 39, of which forms a siftingportion, at least one alignment tray assembly 40, of which forms analignment portion, and a recycle trough 42. The vibratory frame assembly4 is in communication with the pan assembly 6 by way of the plurality ofspring assemblies 18, more particularly, the pan side portions 37 areconnected to the vibratory frame side members 14 by the springassemblies 18. In an exemplary embodiment, each spring assembly 18comprises 1 or more springs 19 with a fastener 41 at both ends of thespring 19, where the fastener 41 secures the springs 19 adjacent to eachother and also secures them to protrusions 43 on both the pan sideportions 37 and the vibratory frame materials, such as, but not limitedto, E-glass/epoxy, carbon fiberglass/epoxy, (carbon/glass)/epoxy,fiberglass/polyester, and high temperature glass/epoxy in cross-ply,spring orientation and unidirectional (e.g., 80%) pre-preg constructionsavailable from Composiflex, Inc., Erie, Pa. In an exemplary embodimentthe protrusions 43 can be cast brackets 17 that are welded in place,although other spring assembly 18 fastening means have beencontemplated. Further, in an exemplary embodiment, three springs 19 canbe used for each spring assembly 18 and thirty-four spring assemblies 18can be used (seventeen spring assemblies 18 located on each side of theapparatus 2). The number of spring assemblies 18 provided are largelydependent on the weight of the pan assembly 6 (greater weight requiresmore springs), and therefore, the number of spring assemblies 18 canincrease or decrease in quantity and size as is necessary to compensatefor the weight.

The motorized vibrator assemblies 16 impart an oscillating force on thepan assembly 6. The frequency of the oscillating force imparted isdependent on the speed of the motor 28, with the speed of motor 28 beingdependent on the accumulation of the spring constants of springs 19versus the weight of the pan assembly 6, as discussed further below. Inan exemplary embodiment the speed can vary from about 600 rpm to about1200 rpm, for example, about 850 rpm, although in other embodiments thespeed can vary from about 100 rpm to about 2000 rpm.

The spring assemblies 18 are oriented at an angle θ below the x-axis 13(as shown in FIG. 2). In an exemplary embodiment θ can be between about15 degrees and about 85 degrees, for example about 45 degrees, althoughin other embodiments θ can vary more or less. In at least oneembodiment, the angle θ can be substantially equal to the angle β.

The selection of spring quantity and spring constants can be derived inone embodiment by the following: given a natural frequency (F_(n) incycles per minute) and pan assembly 6 mass (m in pounds-mass) (i.e., thetotal mass of the pan assembly 6 and the sum of all the individualspring constants (ΣK in pounds per inch)) is equal to the number ofsprings 19 (assuming each spring has the same constant) multiplied by(πF_(n)/30)²(m/386). Thus, the spring constant for each spring 19 is ΣKdivided by the number of springs 19.

In an exemplary embodiment, the spring constant is about 95 pounds/inch,the width of each spring 19 is about 2½ inches, the length of eachspring 19 is about 14 inches and the thickness of each spring 19 isabout ¼ inch, although other values have been contemplated. In anotherembodiment the spring 19 can range in length from about 10 inches toabout 20 inches, the spring 19 thickness can be from about ⅛ inch toabout ½ inch and the spring 19 width can be from about 1 inch to about 4inches, although other values have been contemplated. Additionally, thesize of the spring 19 can control the stroke (distance traveled by thepan assembly 6 as measured from the oscillation spring end secured tothe pan assembly 6). In an exemplary embodiment the stroke can rangefrom about ¼ inch to 1½ inches, more particularly about 1 inch, althoughother values have been contemplated. In terms of overall design, in anexemplary embodiment the spring constant is designed such that theoperating frequency F_(o) of the vibratory frame side members 14 isabout 20-40% of their natural frequency F_(n), more particularly, F_(o)is about 33% of F_(o), although other values have been contemplated. Asdiscussed above, based on the desired size and resultant weight of theapparatus 2, various components, such as the aforementioned, can besized differently as necessary to produce the desired vibratory action.

Further in reference to FIG. 6, the steps 36, the perforated stepassembly 39 and the alignment tray assemblies 40 are situatedsubstantially in-line and form a surface for a food product to travel inorder to apply a coating thereon. In an exemplary embodiment, the steps36 are formed from a continuous piece of substantially planar material,such as metal or plastic that is bent or otherwise formed as a series ofsteps 36 with each step 36 having a ramp portion 54 and a vertical dropportion 56. In one embodiment, the ramp portion 54 can have aninclination angle α from about 5 degrees to 25 degrees, moreparticularly about 15 degrees (as shown in FIG. 2), although othervalues for a have been contemplated. In at least one embodiment, theramp portion 54 and the drop portion 56 comprise substantially planarsurfaces. Additionally, a loading plateau 58 for receiving food productthereon can be situated on or adjacent to the first step 36 located atan inlet end 55 of the pan assembly 6. FIG. 6 depicts an exemplaryembodiment with 6 steps 36, although fewer steps 36 can be used toshorten the process time or apparatus length, and additional steps 36can be used to provide a more thorough coating process. Further, thesteps 36 can be formed from a single piece of material or can be groupedas one or more steps 36 that are formed from multiple pieces ofmaterial, thereby allowing selective removal of only a single step 36 orgroup of steps 36.

Outer step edges 60 (best shown in FIG. 3) of the steps 36 are securedto the pan side portions 37, by one of various methods such as welding,soldering or formed indentations that can receive the steps 36. In oneembodiment, the piece of material that forms the steps 36 can also beused to form the pan bottom portion 34. The material at the bottom of anextended drop portion 57 can be formed at a substantially 90 degreeangle with respect to the extended drop portion 57, such that it formsan extension off the steps 36 that proceeds in a linear manner betweenthe pan side portions 37, such that it is situated underneath theperforated step assemblies 39. Additionally, the pan bottom portion 34can be secured to the pan side portions 37 using welds or a fastenersuch as a bolt. In another embodiment, the pan bottom portion 34 can bea separate piece of material that is secured to the extended dropportion 57.

Further, in an exemplary embodiment, the recycle trough 42 is formed asa portion of the pan bottom portion 34 (best shown in FIGS. 3, 4 and 6)where the recycle trough 42 extends from the pan bottom portion 34diagonally in the direction of a discharge end 59 of the pan assembly 6and in a downward direction of about 10 degrees with respect to the panbottom portion 34, resulting in a trough end 48 being situated about 4to about 6 inches below the pan bottom portion 34. Additionally, in oneembodiment the downward direction of the recycle trough 42 can be fromabout 5 degrees to about 20 degrees. The recycle trough 42 furtherincludes a bottom portion 44 and a wall portion 46. The wall portion 46provides a backstop for recycled coating to abut and therefore bedirected downwards (substantially by vibration) along the bottom portion44 exiting at the trough end 48. Alternative embodiments of the recycletrough 42 can include various other coating exit paths.

Still referencing FIG. 6, in an exemplary embodiment, the pan sideportions 37 secured to the pan bottom portion 34 provide a space forinsertion of the perforated step assembly 39 and the alignment trays 40.In one embodiment, the perforated step assembly 39 comprises perforatedsteps 38 that are similar to steps 36, with the addition of a pluralityof slots 50 formed therethrough (shown in FIG. 3). FIG. 6 depicts theperforated step assembly 39 with three perforated steps 38, althoughfewer steps 38 can be used to reduce the apparatus 2 length or theprocessing time, and conversely, additional lengths can be added tofurther sift the coating from the food product.

In one embodiment, the perforated step assembly 39 further comprises apair of side panels 62 that are each secured to a perforated step edge64 (also shown in FIG. 3) at a substantially perpendicular angle. Theperforated step assembly 39 is sized to be situated adjacent the panside portions 37, the extended drop portion 57, and the alignment trayassembly 40. A pan cross-member 66 comprising a rod 70 and a springlatch 72 extends through apertures in the pan side portions 37. When thespring latch 72 is in a locked position, the perforated step assembly 39is secured in the pan assembly 6, between the pan side portions 37 bythe rod 70. The side panels 62 can further include a handle 68 formed onan upper portion for removal of the perforated step assembly 39 from thepan assembly 6 for cleaning or replacement. In one embodiment, theperforated step assembly 39 can be permanently secured, such as weldedin place or temporarily secured using a fastener, such as a bolt.

Further, regarding the slots 50 formed through the perforated steps 38,in one embodiment the slots 50 are situated at least partiallynon-parallel with respect to the length of the pan side portions 37.Additionally, in an exemplary embodiment, the slots 50 are about 3/16inches wide, have a length of about 3 inches and a center to centerdistance (with respect to width) of about ⅜, although in otherembodiments the slots 50 can vary in range from 3/16 inch to about ½inch wide, have a length of about 3 inches to about 6 inches, and acenter to center distance of about ⅜ inch to about 1 inch. The slots 50allow finer particles of coating situated on the perforated steps 38 topass therethrough and into the recycle trough 42, thereby removingexcess coating from the perforated steps 38 and allowing the coating tobe delivered to the coating recycle assembly 8 for re-use. It has beencontemplated that other embodiments can vary the slot width, length anddirection to accommodate various coatings; for example, a very coursecoating can require a larger size slot 50, and slots 50 situated atspecific angles can be advantageous for some food products. Further, theslots 50 can be formed by various methods, for example drilling orpunching the perforated steps 38.

In FIG. 6, the alignment tray assemblies 40 are shown situated adjacentthe perforated step assembly 39, and between the pan side portions 37.In an exemplary embodiment, the alignment tray assemblies 40 arecomprised of a pair of alignment tray sides 74 and a bottom tray portion76, as shown in FIG. 3. The alignment tray sides 74 are secured atsubstantially perpendicular angles at either side of the bottom trayportion 76. Referring now to FIG. 6, another pan cross-member 66 extendsthrough apertures in both of the pan side portions 37 such that when thecross-member 66 is in a locked position, the alignment tray assemblies40 are secured between the pan side portions 37 of the pan assembly 6.The alignment tray sides 74 can each further include a tray handle 77(best seen in FIG. 4) formed on an upper portion for removal of thealignment tray assemblies 40 from the pan assembly 6 for cleaning orreplacement. Further, in at least one embodiment, the alignment trayassemblies 40 are situated at angle Ω (FIG. 2) that can range from about10 degrees to about 20 degrees, for example 15 degrees, although inanother embodiment this angle can angle can further vary. The upwardangling of the alignment tray assemblies 40 promotes elongation of thefood product as it travels towards the discharge end 59.

In an exemplary embodiment the bottom tray portion 76 is formed as acorrugated piece of metal having tray channels 78 formed by thecorrugations, wherein the tray channels 78 have a top edge 80 and abottom edge 82, as shown in FIGS. 3 and 4, and are used to elongate andalign the food products. In an exemplary embodiment, the inclusive anglebetween adjacent top edges 80 can range from about 60 degrees to about160 degrees, for example 90 degrees, although it has been contemplatedthat in another embodiment the angle can further vary. In an exemplaryembodiment, the top edges 80 can have a spacing there-between of about 35/16 inches, and a height from top edge 80 to bottom edge 82 of about 19/16 inches, although it has contemplated that in another embodiment thetop edges 80 can have a spacing there-between of about 2 inches to about6 inches, and a height from top edge 80 to bottom edge 82 of about oneinch to about four inches. Additionally, the spacing and height can belesser or greater as dictated by the size of the food product beingprocessed.

Additionally, one or more of the top edges 80 can include a separatorpin 84 to guide the food product off the top edge 80 of the traychannels 78. If multiple separator pins 84 are used, they can be instaggered positions as shown in FIG. 3. Staggering can reduce or preventthe blockage of the tray channels 78. The separator pins 84 provide abarrier to force the food product off the top edge 80 and therefore canbe any protrusion that serves this purpose, such as a rod 70 having acircular or triangular cross-section, or a v-shaped metal divider thatimparts separation trajectories pointing away from the oncoming foodproduct. The separator pin 84 can extend in a direction that is towardsthe discharge end 59 of the pan assembly 6 and upward off the top edge80 at an angle of about 1 to about 90 degrees. Additionally, in anexemplary embodiment the separator pin 84 can have a length of about 2¼inches and a diameter of about 3⅛ inches although it has beencontemplated that in another embodiment the length can be from about 1inch to about 3 inches, and the diameter can be about ¼ inch to about 1½inches. Additionally, the length and diameter can be lesser or greateras dictated by the size of the food product being processed with alarger food product requiring a larger length and/or diameter.

Referring to FIG. 3, two exemplary alignment tray assemblies 40 areshown, the first having separator pins 84 and the second having aplurality of tray holes 86 situated along the bottom edge 82 of the traychannel 78. The tray holes 86 can be provided to remove largeragglomerations of coating and/or smaller pieces of food product from thebottom tray portion 76. The tray holes 86 can be of varying diameter andare sized to accommodate the particular type of coating and food productbeing processed, for example, in one embodiment the tray holes 86 canrange from about ¼ inch to about ¾ inch, and have a center to centerspacing of about ⅜ inch to about 1 inch. In an exemplary embodiment, oneor more alignment tray assemblies 40 having separator pins 84 can beused to lengthen and align the food products, and one or more alignmenttray assemblies 40 having tray holes 86 can be used to removeagglomerations, various combinations of alignment tray assemblies 40 canbe used having both separator pins 84 and tray holes 86 or neitherseparator pins 84 and tray holes 86. Further, as shown in FIG. 6, a dustcover 87 is mounted to the support frame 10 and situated substantiallyover the pan assembly 6. The dust cover 87 serves to minimize the dustcreated by the coating process.

Referring to FIGS. 3 and 7, an exemplary coating recycle assembly 8 isdepicted that can be used to recycle coating received from the recycletrough 42 and deliver it to a loading surface 88 on or adjacent to step36. The coating recycle assembly 8 comprises a recycle hopper 90 thatcan be mounted to the support frame 10 or to a separate frame, andpositioned such that recycled coating is directed into the recyclehopper 90 from the recycle trough 42. Additionally, the recycle hopper90 is in communication with a recycle auger 92 and recycle auger housing93 that transfers the recycled coating into a feed hopper 94. The feedhopper 94 can be mounted to the support frame 10 or to a separate frame.The coating is then transferred by a feed auger 96, situated adjacent afeed hopper bottom 97, through an opening 98 onto the loading surface 88of the step 36. Alternatively, the coating can be distributed withoutthe use of the feed auger 96, into a partially enclosed containmentchamber (not shown) as discussed later. In an exemplary embodiment, thefeed hopper 94 is situated at a higher vertical point than the recyclehopper 90; therefore the recycle auger 92 and recycle auger housing 93are positioned to direct the recycled coating at an upwards angle.Additionally, in an exemplary embodiment, the recycle auger 92 and thefeed auger 96 can have about a 6 inch diameter and a pitch of about 6inches. In another embodiment, the augers 92, 96 can have a diameter ofabout 4 to about 10 inches and a pitch of about 2 inches to about 10inches. Further, in other embodiments the augers 92, 96 can vary inlength, diameter and pitch as required by the size of the apparatus 2.In an exemplary embodiment the feed auger 96 is a cross-feed auger,although other embodiments can be modified to use various other stylesof augers. Further, in an exemplary embodiment, the recycle auger 92 isdriven by a recycle auger motor 99 and the feed auger 96 is driven by afeed auger motor 101. Each motor can be a gear motor, although otherdrive mechanisms can be used, such as a hydraulic drive.

Further, referencing FIG. 7, the opening 98 can include a metered slidegate 100 that covers an opening (not shown) in a feed auger containmentchamber 102 situated in the feed hopper 94. In one embodiment theadjustable opening 98 can be manually operated, although it has beencontemplated that the slide gate 100 can be controlled automatically.Alternatively, the slide gate 100 can be omitted and/or a fixed openingcan be used. In one embodiment, a coating level sensor 104 (shown inFIG. 6), such as an ultrasonic sensor, can be situated adjacent theloading surface 88 and used for measuring the height level of thecoating situated on the loading surface 88. It has been contemplatedthat the coating level sensor 104 can be one of a variety of sensorsappropriate for use with particles, such as an inductive proximitysensor, a laser or a paddle wheel. In one embodiment, the coating levelsensor 104 can be used to signal the feed auger 96 to slow down or speedup to control the flow of coating to the loading surface 88.Additionally, in another embodiment the coating level on the loadingsurface 88 can be controlled by the speed of the feed auger 96 and/orthe recycle auger 92, or the speed of the feed auger motor 101 and/orrecycle auger motor 99. In an exemplary embodiment, the desired depth ofcoating can range from about ½ inch to about 2 inches above the loadingsurface 88. Further, in an exemplary embodiment, a relief valve (notshown) such as an opening with a biased cover-flap, can be situatedadjacent the feed auger containment chamber 102 to provide for thedischarge of excess coating.

To begin operation of the exemplary apparatus 2, the motorized vibratorassemblies 16, recycle auger motor 99 and feed auger motor 101 areactivated. The speed of the vibrator assemblies 16 is adjusted toachieve a predetermined frequency and amplitude. Coating is charged intothe recycle hopper 90 and is fed via the recycle auger 92 to the feedhopper 94. The feed hopper 94 funnels the coating into the feed augercontainment chamber 102 and to the feed auger 96. The feed auger 96 thenmoves the coating onto the loading surface 88 through the metered slidegate 100. If the coating level sensor 104 detects that the coating levelon the loading surface 88 is sufficient, the metered slide gate 100 willreduce or cease the flow of coating to the loading surface 88. Thecoating is then distributed from the loading surface 88 throughout thepan assembly 6 and coating recycle assembly 8. As shown in FIG. 8, afterthe coating has been distributed, the food product is fed onto theloading plateau 58 by a means such as a metered conveyor 106 that issupplied by a conveyor hopper 108 or a batter applicator (not shown).The food product moves in a forward direction (from the inlet portionend 55 of the pan assembly 6 towards the discharge end 59 of the panassembly 6) using the vibrations transferred from the vibratory frameassembly 4 to the pan assembly 6. The vibrations thrust the food productand the coating at about a 45 degree angle towards the discharge end 59,resulting in a forward movement up and over each of the steps 36, withthe vertical component of the vibration patting coating to the undersideof the food product and the horizontal component moving the food productforward. Further, the step 36 configuration results in the food productbeing rolled and tumbled as it falls off the drop portion 56, such thatthe food product is spread apart and coating is applied to multiplesurface portions of the food product in a manner that is similar to ahome-style application.

Once the coating has been applied to the food product along steps 36,the food product moves onto the perforated step assembly 39 and alongthe perforated steps 38. The perforated steps 38 continue to roll ortumble the food product in the same manner as steps 36, resulting insome coating being further secured to the food product and some coatingfalling off of the food product and the perforated step assembly 39, andonto the bottom tray portion 76. The smaller coating particles then fallthrough the slots 50 in the perforated steps 38 and down into therecycle trough 42. The food product continues moving forward onto thealignment tray assembly 40. As the food product enters the alignmenttray assembly 40, it becomes biased by the tray channels 78 in thebottom tray portion 76. As the food product moves along the bottom trayportion 76, the tray channels 78 tend to shift the food product from thetop edges 80 into the bottom edges 82. Because the alignment trayassembly 40 has an inclination angle, the food product is elongated asit moves up the bottom tray portion 76. Food product that is positionedsubstantially across the top edge 80 of the bottom tray portion 76 canencounter a separator pin 84, which tends to force the upward movingfood product to shift off the top edge 80 towards the bottom edge 82. Inan exemplary embodiment, a second alignment tray assembly 40 having trayholes 86 can be provided adjacent the first alignment tray assembly 40.The second alignment tray assembly 40 receives the food product from thefirst alignment tray assembly 40 and similarly provides furtherelongation of the food product. The tray holes 86 allow undesirablysmall food product pieces and/or agglomerations of coating that did notfall through the slots 50 to fall through the bottom tray portion 76 andbe collected separate from the coating collected by the recycle trough42, thereby removing unwanted material from the process. The foodproduct continues to move across the second alignment tray 40 and ontoan off-loading device such as a conveyor belt (not shown) to be furtherprocessed. In other embodiments, a single alignment tray 40 can be usedhaving the separator pins 84 and/or the tray holes 86. Additionallymultiple alignment trays 40 can be used having the separator pins 84and/or the tray holes 86, the number of alignment trays 40 being largelydependent on the acceptable size of the apparatus 2.

The alignment tray 40 and other portions of the apparatus 2 can bedesigned to be the same width of conveyor belts and other devices usedwith the apparatus 2 such that the food product can move between theapparatus 2 and other devices without rearranging the width of path ofthe food product traveling through the apparatus 2.

In addition, the food product exits the apparatus 2 at substantially thesame elevation as it enters the apparatus 2, thereby avoiding having toadjust the height of other devices used with the apparatus 2 andavoiding having workers having to adjust their stance when working onthe apparatus 2.

Still further, the pan assembly 6 can be configured to be as wide ornarrow as other process equipment used in conjunction with the apparatus2, such as a conveyor used to off-load food product. For example, thepan assembly 6 can be 24″, 34″ or 40″ wide, although additional widthsare also within the scope of the invention. By using pan assembly 6widths that are the same width as other food processing equipmentlocated either at the inlet end 55 or the discharge end 59 of theapparatus 2, throughput of food product is less likely to be inhibitedthroughout a process. In addition, the use the alignment tray assembly40 can eliminate the need for a secondary process of spreading andaligning food product to a desired position, thereby improvingthroughput.

Further, regarding the coating recycle assembly 8, the coating thatfalls through the slots 50 in the perforated steps 38 is substantiallyreceived by the wall portion 46 and bottom portion 44 of the recycletrough 42. The coating is then moved substantially by the oscillatingvibrations down the recycle trough 42 and exits through the trough end48 into the recycle hopper 90. The coating in the recycle hopper 90 istransferred by the recycle auger 92 and recycle auger housing 93 to thefeed hopper 94, thereby allowing the coating to be recycled and appliedto incoming food product.

Another exemplary coating recycle assembly 200 that can be used with theapparatus 2, is shown in FIG. 9. The coating recycle assembly 200 canfunction without augers, wherein the use of an augerless coating recycleassembly 200 can be more suitable for fine and/or delicate coatings. Thecoating recycle assembly 200 includes a fill hopper 204 and a recycleconveyor 210. Utilizing the recycle conveyor 210, the coating recycleassembly 200 can recycle the coating without the need for one or moreaugers, thereby reducing the turbulence experienced by the coatingduring the recycling process. The recycle conveyor 210 includes aconveyor channel 212 that is mounted to a frame 206 and a drag-chainbelt 214 situated at least partially within the conveyor channel 212.The conveyor channel 212 can include an inner side portion 213, an outerside portion 215, a bottom portion 217 and a removable top portion 219.In one embodiment, the drag-chain belt 214 is a solid synthetic withtracking lugs (or drive cogs) (not shown) on one side and flights 216 onthe opposite side. The lugs can be secured to the drag-chain belt 214using a fastener or they can be integrally molded with the drag-chainbelt 214 thereby eliminating crevices, fissures, hinges or otherstructures where coatings and/or topping can become lodged and impedecleaning of the belt. In at least one embodiment, the drag-chain belt214 can be made of polyester thermal plastic, polyurethane, or anothermaterial that can be sufficiently cleaned to meet food process industrystandards. An exemplary drag-chain belt 214 is a SuperDrive from Voltaof Karmiel, Ill. Another exemplary drag-chain belt 214 is a plasticflighted belt, a Series 800 Open Hinge Impact Resistant Flight modelavailable from Intralox, LLC of Harahan, La.

The flights 216 can vary in size to accommodate the transport of more orless coating, although in one embodiment, the flights 216 are 6 inchesby 6 inches. Further, the flights 216 can be oriented at various angleswith respect to the inner and outer side portion 213, 215, and thebottom portion 217, although in one embodiment the flights 216 areoriented perpendicular to each of the inner and outer side portion 213,215, and the bottom portion 217. Further, the flights 216 can besituated such that free ends thereof are perpendicular to and pointtoward the outer side portion 215.

In an exemplary embodiment, the recycle conveyor 210 is in a rectangularconfiguration having four corners, where one of the corners includes asprocketed drive 209 that engages the cogs of the drag-chain belt 214,and the other three corners have drive belt rollers 211 for guiding theabutted drag-chain belt 214, to form a rectangular shape. The sprocketeddrive 209 is received on a drive shaft (not shown). An overhung loadadaptor (not shown) and a conveyor motor (shown in FIG. 12 as 307), suchas a hydraulic or electric motor, are used to rotate the drive shaft.Additionally, the use of a rectangular shaped recycle conveyor 210permits the drag-chain belt 214 to be wrapped around the apparatus 2,thereby allowing a reduction in the overall footprint of the apparatus2. Although the recycle conveyor 210 is shown and described asrectangular, other configurations can be used as well, for example,circular or square.

Further referencing FIG. 9, the conveyor channel 212 includes an upperlength 218, a lower length 220, an ascending portion 222, and adescending portion 224. The upper length 218 includes a channel opening202 in the conveyor channel 212 configured to allow recycled coating toflow from the conveyor channel 212 onto a surface below, such as theloading surface 88 or a food product top surface.

With the coating recycle assembly 200, the coating is initially fed intothe fill hopper 204 where it is carried by the drag chain belt 214 upthe ascending portion 222 and across the upper length 218 of the coatingrecycle assembly 200. It is then deposited through a base channelopening 202 in the center of the upper portion of conveyor channel 212.Coating that passes through the base channel opening 202 can becollected in a feed hopper 94 (FIG. 7) or the coating can proceeddirectly to the loading surface 88 or the loading plateau 58, asdiscussed below. The coating flow can then be metered out of the feedhopper 94 by an adjustable opening (not shown) where it can be directedinto a distribution portion such as channels (not shown) and a trough(not shown). The distribution portion can deposit substantially equalamounts of coating onto each side of the loading surface 88, wherein thecoating is then spread across the width of the loading surface 88 by theuse of a transverse distribution means (not shown) and/or with theassistance of a conveying device such as an auger (not shown). Thecoating is then carried forward by the vibratory action and moves up theramp portion 54 (as seen in FIG. 6) and down the drop portion 56 untilit reaches the discharge end 59 (FIG. 6) of the pan assembly 6 (FIG. 6)and is deposited into the lower length 220 of the recycle conveyor 210.

In another embodiment as shown in FIG. 11, a coating recycle assembly200A is provided that can include a fill hopper (not shown) and a baserecycle conveyor 210A. The base recycle conveyor 210A has a channelopening 202A to provide a flow of coating into a containment chamber225A situated adjacent to the loading surface 88 (not shown). Thecontainment chamber 225A includes three barrier walls 228A that extendfrom the channel opening 202A towards the loading surface 88. Thebarrier walls 228A are combined with a partial dam wall 221A and achamber opening 230A to form a perimeter about the containment chamber225A. The chamber opening 230A can be metered with a chamber dam 232A.The chamber dam 232A is movably attached to the partial dam wall 221A,wherein the chamber dam 232A can be positioned closer or farther awayfrom the loading surface 88 to open or close the chamber opening 230Athereby metering the amount of coating that exits the containmentchamber 225A onto the loading surface 88. Further referencing FIG. 11,the base recycle conveyor 210A includes a drain trap 245A. The draintrap 245A provides an exit path for removing coating situated in thebase recycle channel 210A. The drain trap 245A includes a drain barrier248A that is slidingly adjustable to allow the recycle coating in theconveyor channel 212A to flow out of the conveyor channel 212A only whendesired.

Although some processes can use a single recycle conveyor 210A toprovide coating to a food product, other processes can benefit from theuse of more than one recycle conveyor 210A. The use of multipleconveyors provides added flexibility to the apparatus 2 to providecoating at various positions along the pan assembly 6 and on varioussurfaces of the food product. For example, as shown in FIG. 12, anexemplary coating recycle assembly 200B can include a fill hopper (notshown), a base recycle conveyor 210A and a waterfall recycle conveyor210B. In one at least one embodiment, the base recycle conveyor 210Autilizes a containment chamber 225A to provide a supply of coating tothe loading surface 88 (see FIG. 6), for covering at least the bottomportion of the food product. In addition, the waterfall recycle conveyor210B includes a containment chamber 225B to provide a supply of coatingvia a chamber opening 230B adjacent the loading plateau 58 (see FIG. 6)to cover at least a top portion of the food product. Alternatively, thecoating that exits the chamber opening 230B can be deposited onto awaterfall ramp 252B (see FIGS. 10 and 13). The waterfall ramp 252Bprovides a planar surface for receiving the coating. The waterfall ramp252B extends as necessary to direct the coating to fall upon the foodproduct situated below, for example adjacent the pan assembly 6. Thewaterfall ramp 252B is mounted to the pan assembly 6 and as a result, issubjected to the vibration of the pan assembly 6. The waterfall ramp252B can be mounted at a descending angle, such that the vibrationscause the coating, situated thereon, to flow along and off the waterfallramp 252B in a waterfall manner to provide a wall of coating as the foodproduct is passed underneath. In another embodiment, a sifting plate(not shown) can be situated below the waterfall channel opening 202B orthe chamber opening 230B to at least partially catch the coating, withthe sifting plate being secured to a portion of the apparatus 2 thatvibrates, such as the pan assembly 6. In one embodiment the siftingplate is rectangular with a plurality of slots therethrough. The siftingplate can be inclined so as to act as a dam allowing the coating thatfalls thereon to spread more evenly, and in at least one embodiment canprovide a metered distribution.

As discussed previously, coating that does not adhere to the foodproduct is discharged at the discharge end 59 of the pan assembly 6.Discharged coating can flow into either the base recycle conveyor 210Aor the waterfall recycle assembly 210B to be recycled. As the demand forcoating can vary between the containment chambers 225A and 225B, ametering plate 254 (FIG. 13) is situated adjacent the discharge end 59of the pan assembly 6. The metering plate 254 can comprise of a planarmeter portion 256 that has a meter opening 258 therein, controlled by asliding planar meter plate 260. The meter plate 254 receives the coatingat the discharge end 59 and can direct at least a portion of it, overthe waterfall recycle conveyor 210B and into the base recycle conveyor210A. The metering is provided by moving the metering plate 254 inposition to cover or uncover the meter opening 258.

When utilizing the base recycle conveyor 210A and the waterfall recycleconveyor 210B in combination, the coating recycle assembly 200B can usea single conveyor motor 262B to drive both drag-chain belts and use asingle fill hopper 204B (as shown in FIG. 14 mounted on a waterfallrecycle conveyor 210B). Although, in at least some embodiments, separateconveyor motors 262B can be used to drive each of the drag-chain belts(FIG. 13) and the fill hopper 204B can be situated on one or both of theconveyors 210A and 210B. Additionally, an auxiliary hopper/conveyor 264Bcan be used to supply coating to the fill hopper 204B, as seen in FIG.14.

The aforementioned coating recycle assemblies 200, 200A and 200B can beused with an apparatus 2 that includes a wire conveyor belt assembly 400(see FIGS. 15A and 15B) as described below. The coating of fragile foodproducts that can not endure the rigors of traveling along the steps ofthe pan assembly 6 can be accommodated by the wire conveyor beltassembly 400. Further, the use of wire conveyor belt assembly 400 canallow for the application of a coating or topping to only a top orbottom portion of the food product. In at least one embodiment, when thewire conveyor belt assembly 400 is used with the coating recycleassembly 200B, the base recycle conveyor 210A can provide a fresh orrecycled supply of coating to a loading surface of the wire conveyorbelt assembly 400 for coating at least a bottom portion of a foodproduct, and the waterfall recycle conveyor 210B can provide fresh orrecycled coating to at least a top portion of a food product situated onthe wire conveyor belt assembly 400. An exemplary embodiment of the wireconveyor belt assembly 400, as seen in FIGS. 15A and 15B, includes aproximal end 401 for the intake of coating and food product and a distalend 405 for offloading the food product. The wire conveyor belt assembly400 further comprises a housing 403, a wire conveyor belt 402 and adrive shaft 404 for actuating the belt 402. Various rollers are includedsuch as support rollers 408 and a hold down roller 410 for altering thepath of the belt 402. Additionally, an adjustable roller 412 is includedto take up slack in the belt 402. Further, a roller 414 is moveablyreceived in an arcuate groove 416 of a sidewall 418 of the housing 403,as described below. The wire conveyor belt assembly 400 also includestwo roller cylinders 426 situated above the belt 402 to press coatingand/or topping onto the food product as it passes along the wireconveyor belt 402.

Further, the wire conveyor belt 402 includes an upper conveying surface422 and a lower conveying surface 424. The arcuate groove 416 allowsreorientation of the upper conveying surface 422 with respect to thelower conveying surface 424 and thus, reorientation of the wire conveyorbelt 402. Placing the roller 414 at the upper end of the arcuate groove416 results in the food product moving off the upper conveying surface422 and landing on the lower conveying surface 424 with the side of thefood product that contacted the upper conveying surface 422 now beingopposite the side of the product that contacts the lower conveyingsurface 424. That is, the food product is flipped when it transfers fromthe upper conveying surface 422 onto the lower conveying surface 424. Abenefit of flipping the food product is that when coatings or toppingsare lightweight and airy materials, such as flour, flipping food productremoves unattached coatings or toppings. As seen in FIG. 15A, in atleast one embodiment the wire conveyor belt assembly 400 includes a beltsupport pan 420 situated underneath a portion of the lower conveyingsurface 424. The belt support pan 420 provides support to the wireconveyor belt 402 and to the coating that is situated under the wireconveyor belt 402. As the wire conveyor belt 402 travels along, itcarries at least a portion of the coating situated underneath.

To provide an apparatus 2 that is capable of universally and selectivelyapplying coatings and toppings to one or more portions of both durableand fragile food products, an exemplary apparatus 2 can include the wireconveyor belt assembly 400, wherein the wire conveyor belt assembly 400is at least partially removably situated in a position that is adjacentthe pan assembly 6, as discussed below. Referring to FIGS. 16 and 22(the vibratory frame assembly 4 and pan assembly 6 are not shown forclarity purposes), in an exemplary embodiment, the wire conveyor beltassembly 400 is suspended by a swing frame portion 500 to create a wirebelt swing assembly 501. The swing frame portion 500 can be secured to aseparate swing frame 506 or to at least one of the frames 10 and 306(FIGS. 5 and 12, respectively). The swing frame portion 500 isconfigured to support the wire conveyor belt assembly 400 such that itis isolated from vibrations of the vibratory frame assembly 4 and panassembly 6. The wire conveyor belt assembly 400 is suspended by theswing frame portion 500 with arms 502 on either side. The arms 502 arehinged at both the swing frame portion 500 and at the wire conveyor beltassembly 400. In reference to FIGS. 16 and 22, the arms 502 are hingedat ends of proximal and distal transverse supports 508, 510, which aresupported on the upper side members 512, 514 by brackets 516. The arms502 have a geometry that allows the wire conveyor belt assembly 400 toswing out of an operating position (FIG. 16) and into a non-operationposition (as shown in FIG. 21). The swinging motion can be powered by ahydraulic cylinder 518, a pneumatic cylinder, or the like. The hydrauliccylinder 518 is connected to a torque arm 520 and then to a lever shaft522 that makes up one of the upper hinge points. The lever shaft 522transmits torque into one set of the arms 502 to create a motion thatswings the wire conveyor belt assembly 400 into the non-operatingposition. The motion could also be accomplished using a rotary actuator,an electromechanical jack, or similar devices.

Referring to FIGS. 13 and 18, the wire belt swing assembly 501 can beutilized with one of the various coating recycle assemblies 200A, 200B.Additionally, the wire belt swing assembly 501 can be utilized inconjunction with a combination of the coating recycle assembly 200A,200B, the vibratory frame assembly 4 and the pan assembly 6. Further,the wire belt swing assembly 501 can be configured such that the wireconveyor belt assembly 400 can swing in and out of a production positionwithout making contact with other equipment, such as the coating recycleassembly 200A, 200B, the vibratory frame assembly 4 and pan assembly 6.

In at least one embodiment, the recycle assembly 200B and the wire beltswing assembly 501 can be secured to the frame 10 of the vibratory frameassembly 4, and used in conjunction with the pan assembly 6 (FIG. 13).This provides the apparatus 2 with the versatility to apply a multitudeof coatings, breading and toppings to numerous types of food products.For example, as shown in FIG. 17, the wire conveyor belt assembly 400can be placed in a non-production position to enable unfettered use ofthe pan assembly 6, for coating multiple sides of durable food products,as previously described. In this position, the base recycle conveyor210A is used to convey coating to the loading surface 88 via the basecontainment chamber 225A. As the food product and coating are moved byvibratory action across the pan assembly 6, the food product is coated.Discarded coating that reaches the discharge end 59 of the pan assembly6 is deposited into the lower length 220A of the base recycle conveyor210A by adjusting the metering plate 328 (FIG. 13) so that the coatingavoids the waterfall recycle conveyor 210B. Additionally, although notnecessary, the waterfall recycle conveyor 210B can be used to provideadditional coating onto the food product if desired and can besubsequently recycled as well by adjusting the metering plate 328.

Alternatively, the wire conveyor belt assembly 400 can be situated in aproduction position to substantially by-pass the steps 36 of the panassembly 6. This position can be used for coating less durable foodproducts that cannot tolerate the agitation of the steps 36.Additionally, this position allows selective coating of the top and/orbottom portions only of the food product. When using the wire conveyorbelt assembly 400, the pan assembly 6 is modified to facilitate movingcoating onto the proximal end 401 of the wire conveyor belt assembly 400(FIGS. 15A and 15B), as opposed to the steps 36 (FIG. 6). The panassembly 6 is also modified to catch and remove unwanted portions offood product and coating that fall off of the belt support pan 420. Toload coating onto the wire conveyor belt assembly 400, the proximal end401 is situated such that coating will be deposited thereon, instead ofcontinuing along the steps 36 of the pan assembly 6. In one embodiment,step 36 that is part of or succeeds the loading plateau 58 (see FIG. 6)can be removed, to allow the proximal end 401 of the wire conveyor beltassembly 400 to be inserted under the loading plateau 58. In anotherembodiment as seen in FIG. 13, a modified step 36A having a loadingplateau 58A can replace the step 36, wherein the modified step 36A issimilar to the first series of steps 36 with the exception that theloading plateau 58A extends as to allow the proximal end 401 of the wireconveyor belt assembly 400 to be positioned underneath the loadingplateau 58 and in position to receive coating that is vibrated off theloading plateau 58.

While the wire conveyor belt assembly 400 is operating the pan assembly6, situated underneath, acts to catch and remove portions of foodproduct and coating that fall off the belt support pan 420 and throughthe drag-chain belt 214. In one embodiment, the perforated step(s) 38 ofthe pan assembly 6 can be removed and replaced with one of variousfiltering configurations to accommodate a particular size and texture ofbreading, although the perforated steps 38 can also be utilized toprovide the filtering. In addition, other steps or trays can be utilizedalong the pan assembly 6 to provide filtering. The coating that fallsthrough the filtering configuration, such as the perforated steps 38, isvibrated towards the discharge end 59. Coating at the discharge end 59is then vibrated across or through the metering plate 328 and into atleast one of the base recycle conveyor 210A and waterfall recycleconveyor 210B. The larger agglomerations of coating and food productthat have been separated from the recycled coating are vibrated acrossthe top of the perforated steps 38 and deposited into a waste receiver(not shown). Further, the aforementioned apparatus 2, without the wirebelt swing assembly 501, can be used with the coating recycle assembly200, 200A, 200B as a stand alone food coating apparatus. Alternatively,the apparatus 2 can be used with the coating recycle assembly 200, 200A,200B and the wire belt swing assembly 501, to form a multi-use coatingapparatus 2.

In addition to the aforementioned embodiments of the apparatus 2,another exemplary embodiment of the apparatus 2 is depicted in FIG. 19,wherein product coating portion coating is applied to the food productusing vibrational forces to move the food product and coating down aseries of steps 36C. As the food product falls from an upper step 36C toa lower step 36C, the food product can flip and twist allowing foldedportions of the food product to unfold. The unfolded portions of thefood product are then exposed to the coating situated along the steps36C, thereby allowing the application of coating to multiple surfaces ofthe food product as it progresses down the steps 36C. Similar to theaforementioned embodiments discussed above, the apparatus 2C provides acoating to a pan assembly 6C, wherein the pan assembly 6C is connectedto a vibratory frame assembly 4C by spring assemblies 18C. Motorizedvibrator assemblies 16C are mounted on the vibratory frame side members612 to provide the vibratory energy. While this embodiment illustratesthe use of two motorized vibrator assemblies 16C, a single motorizedvibrator assembly 16C may be used. In all embodiments, one, two, or morevibrator assemblies 16C can be used.

Further, in the embodiment shown in FIG. 19, the pan assembly 6Cincludes a continuous series of steps 36C. The number of step 36C canvary depending upon the food product being coated. In the exemplaryembodiment shown in FIG. 19 there are six steps 36C. In addition, thevibrator assemblies 16C are mounted to impart energy to the vibratoryframe side members 14C at an angle β below x-axis 13C. In oneembodiment, this angle can be about 22.5 degrees, although other angles,such as about 45 degrees, have been contemplated. Further, the springassemblies 18C are mounted at an angle θ below the x-axis 13C that, inat least one embodiment, is substantially equal to β.

In use, coating is provided to a feed hopper 94C as discussed below. Thefeed hopper 94C distributes the coating onto a loading surface 88C of ametered conveyor 106C. The metered conveyor 106C is also used todistribute the food product to a loading plateau 58C situated on theuppermost step 36C of the pan assembly 6C. Food product is depositedfrom the metered conveyor 106C onto the loading plateau 58C. Thevibrational forces imparted on the pan assembly 6C move the food productforward along the uppermost step 36C. When food product travels to theend of the uppermost step 36C, it falls onto the next step 36C, that is,the next surface of the pan assembly 6C. Coating that has not adhered tothe food product also moves along the steps 36C and coats the foodproduct as both travel along the steps 36C. When the coated food productreaches the end of the pan assembly 6C, it is discharged onto anotherdevice, such as a discharge conveyor (not shown). The coating that hastraveled along the pan assembly 6C that does not adhere to the foodproduct is also discharged. The discharged coating can be removed aswaste or it can be recycled using a coating recycle assembly 200C thatincludes a recycle conveyor 210C. The discharged coating is dropped intothe recycle conveyor 210C directly or through a filter component, suchas a scalping screen (not shown), and the recycle conveyor 210Ctransports the coating to the feed hopper 94C. A channel opening (notshown) in the recycle conveyor 210C allows coating to be discharged fromthe recycle conveyor 210C into the feed hopper 94C. In addition, in atleast one embodiment, the recycle conveyor 210C can deposit coatingdirectly onto the loading surface 88C thereby eliminating the feedhopper 94C as discussed above.

In an exemplary embodiment and as discussed above, the apparatus 2 canapply coatings and toppings including but not limited to, flour,breading, sugar, cheese and spices, to food products, such as pizzas,vegetables, fruits, durable and fragile meat products, and confections.Additionally, in other embodiments, the apparatus 2 can be suitable forapplying various consistency coatings and toppings to various foodproducts. Further, although an exemplary apparatus 2 has been describedabove with respect to coating food products, it has been contemplatedthat in other embodiments the apparatus 2 can be used with non-foodproducts as well, for example, applying non-food particulates of varyingsize to the outside of a non-food product, for example, applying glitterto an ornament.

The components and sub-components of the aforementioned apparatuses 2can be formed from metal, such as stainless steel, although it has beencontemplated that other materials may be used such as plastic or mildsteel with a protective coating. Further, the apparatuses 2 can beconfigured to be wider or narrower to accommodate space constraints andfood production capacity requirements. Additionally, the numericalranges in this disclosure are approximate, and thus may include valuesoutside of the range unless otherwise indicated.

In addition, all of the hydraulic and electronic components discussedherein can be controlled by a programmable device such as a programmablelogic controller (PLC) or can be provided with various manual orautomatic discreet controls, for example hand operated starters anddrive controllers.

While this invention has been described in conjunction with theexemplary embodiments outlined above, various alternatives,modifications, variations, improvements, and/or substantial equivalents,whether known or that are or may be presently unforeseen, may becomeapparent to those having at least an ordinary skill in the art.Accordingly, the exemplary embodiments of the invention as set forthabove are intended to be illustrative, not limiting. Various changes maybe made without departing from the spirit and scope of the invention.Therefore, the invention is intended to embrace all known or earlierdeveloped alternatives, modifications variations, improvements and/orsubstantial equivalents. It is specifically intended that the presentinvention not be limited to the embodiments and illustrations containedherein, but include modified forms of those embodiments includingportions of the embodiments and combinations of elements of differentembodiments as come within the scope of the following claims.

1. An apparatus for applying coating to products comprising: a vibrationgenerating portion, for providing a vibratory motion, and a productcoating portion, for receiving the vibratory motion and applying acoating to a product; wherein, the vibration generating portioncomprises a vibratory frame assembly that includes a motor vibrationassembly, and the product coating portion includes a pan assembly,wherein the vibratory frame assembly is in communication with the panassembly by spring assemblies that move the pan assembly with avibratory motion; and wherein the pan assembly includes at least one ofa coating application portion, a sifting portion, and an aligningportion; and wherein when included, the sifting portion succeeds thecoating application portion.
 2. The apparatus of claim 1 furtherincluding, a recycle conveyor for collecting the coating that does notadhere to the product and returning the coating to the product coatingportion for application to other products.
 3. The apparatus of claim 1wherein the coating that passes through the sifting portion is collectedand guided into at least one of a hopper and a recycle conveyor thatconveys the coating back to the coating application portion.
 4. Theapparatus of claim 3 wherein the aligning portion further comprises acorrugated surface situated at an incline having tray channels formed bythe corrugations that are substantially parallel with the length of thepan assembly, the tray channels being situated to bias the product suchthat it can be elongated and aligned from the vibrations.
 5. Theapparatus of claim 4 wherein an additional sifting portion can beprovided that comprises another aligning portion having holes situatedthere-through to allow agglomerations of coating and fragmented productto pass through, thereby removing them from the process.
 6. Theapparatus of claim 1 further including a recycle conveyor for recyclingcoating, wherein the recycle conveyor includes a conveyor channel havinga lower length, an upper length, an ascending portion and a descendingportion, and a belt having one or more flights situated at leastpartially in the channel for transporting coating from the lower lengthto the upper length via the ascending portion, with the lower length ofat least one channel receiving coating from one end of the apparatus,and the upper length releasing coating at another end of the apparatusadjacent to the product coating portion.
 7. An apparatus for applyingcoating to products comprising: a belt assembly capable of receivingcoating and food products and applying the coating to the products, apan assembly capable of receiving coating and products and applying thecoating to the products, and a vibration generating portion forproviding a vibratory motion to the pan assembly, wherein the apparatusfurther includes a recycle conveyor for collecting coating that does notadhere to the product and supplying the coating for application to atleast one of a bottom and top portion of a product; and wherein therecycle conveyor includes a conveyor channel having a lower length, anupper length, an ascending portion and a descending portion, and a belthaving one or more flights situated at least partially in the channelfor transporting coating from the lower length to the upper length viathe ascending portion, with the lower length of at least one channelreceiving coating from a discharge end of the pan assembly, and theupper length of at least one channel releasing coating adjacent an inletend of the pan assembly.
 8. The apparatus of claim 7 wherein the recycleconveyor comprises a base recycle conveyor.
 9. The apparatus of claim 7wherein the recycle conveyor comprises a waterfall recycle conveyor. 10.The apparatus of claim 7 wherein the vibration generating portioncomprises a vibratory frame assembly that includes a motor vibrationassembly in communication with the pan assembly by springs that arecapable of moving the pan assembly in a vibratory motion, and a supportframe isolated from the vibratory motion.
 11. The apparatus of claim 10wherein the support frame includes a swing frame portion that supportsthe wire conveyor belt assembly, such that the wire conveyor beltassembly is movable from a non-production position to a productionposition, wherein the production position allows product to betransported on the wire conveyor belt assembly.
 12. The apparatus ofclaim 11 wherein the pan assembly includes at least one of a coatingapplication portion, a sifting portion, and an aligning portion.
 13. Theapparatus of claim 12 wherein the coating application portion furthercomprises one or more steps that utilize the vibratory motion to guidethe coating and the product up and over each step, while simultaneouslyallowing the product to be vibrated against the coating on the stepsurface.
 14. The apparatus of claim 13 wherein the sifting portionsucceeds the coating application portion and where the product continuesto vibrate across one or more steps.
 15. The apparatus of claim 14wherein the one or more steps include slots formed therein, and whereexcess coating flows through the slots, the coating that passes throughthe slots is collected and guided into at least one of a hopper and therecycle conveyor.
 16. The apparatus of claim 15 wherein the aligningportion further comprises a corrugated surface situated at an inclinehaving tray channels formed by the corrugations that are substantiallyparallel with the length of the pan assembly, the tray channels beingsituated to bias the product such that it can be elongated and alignedfrom the vibrations.
 17. The apparatus of claim 16 further comprising anadditional sifting portion that includes another aligning portion havingholes situated there-through to allow agglomerations of coating andfragmented product to pass through, thereby allowing them to be removedfrom the steps.
 18. A method for applying coating to productscomprising: receiving coating at an inlet end of a pan assembly forapplication to a product, vibrating the pan assembly using a vibratoryframe assembly connected thereto, positioning the product at the inletend of the pan assembly, removing excess coating from at least a portionof the pan assembly, receiving the product at the discharge end of thepan assembly, and receiving the excess coating at the discharge end ofthe pan assembly and transporting it to the inlet end of the panassembly.
 19. The method of claim 18 including positioning a beltassembly supported above and adjacent to the pan assembly, in anon-production position such that the belt assembly is not adjacent tothe pan assembly.
 20. The method of claim 18, wherein the coating isreceived at the inlet end of the pan assembly from a recycle conveyor,and the excess coating is received by the recycle conveyor at thedischarge end.
 21. A method for applying coating to products comprising:receiving coating at an inlet end of a pan assembly, positioning aproximal end of a belt assembly adjacent to the inlet end of the panassembly, vibrating the pan assembly, such that coating situated at theinlet end of the pan assembly is transported by vibratory motion to theproximal end of the belt assembly, positioning a product at the proximalend of the belt assembly, conveying the product from the proximal end ofthe belt assembly to a distal end, wherein coating is applied to theproduct during at least a portion of the conveyance, receiving excesscoating from the belt assembly and transporting the excess coating alongthe pan assembly to the discharge end of the pan assembly using thevibratory motion, and receiving the excess coating from the dischargeend of the pan assembly in a recycle conveyor, and transporting it to atleast one of the inlet end of the pan assembly and the proximal end ofthe belt assembly.
 22. The method of claim 21 wherein the belt assemblyis supported by a swing frame, such that it is capable of beingpositioned in production and non-production positions.
 23. A coatingrecycle assembly comprising: a recycle conveyor that includes a conveyorchannel having a lower length, an upper length, an ascending portion anda descending portion, and a belt having one or more flights situated atleast partially in the channel for transporting coating from the lowerlength to the upper length via the ascending portion, where coating isreceived at the lower length and is released at the upper length. 24.The coating recycle assembly of claim 23, wherein the recycle conveyorreceives coating at the lower length from the discharge end of a panassembly.
 25. The coating recycle assembly of claim 24, wherein thecoating is transported from the lower length of the recycle conveyor toan inlet end of the pan assembly for application to at least one of abottom portion of a product and top portion of a product.
 26. Thecoating recycle assembly of claim 25, the pan assembly is vibrated by avibration generating portion to convey the product along the panassembly to apply the coating to the product.
 27. A method of conveyingcoating comprising: rotating a belt having one or more flights situatedat least partially in a conveyor channel of a recycle conveyor;receiving coating at a lower length of the conveyor channel;transporting the coating from the lower length to an upper length via anascending portion of the conveyor channel situated between the lowerlength and upper length; releasing the coating at the upper length ofthe conveyor channel.
 28. A method of conveying coating of claim 27,wherein the coating received at the lower length includes recycledcoating that was in contact with a food product.